Sheet counting system in a reproduction machine



March 4, 1969 J. R. cAssANo 3,430,558

SHEET COUNTING SYSTEM IN A REPRODUCTION MACHINE Filed Sept. 30, 1965Sheet of 13 INVENT OR. JAMES RCASSANO BYyw /rf/u March 4, 1969 J. R.CASSANO SHEET couunue SYSTEM IN A REPRODUCTION MACHINE Filed Sept. 30,1965 Sheet N at mvsmon. JAMES RCASSANO lax/24 ATTORNEYS March 4, 1969 J.R. CASSANO SHEET COUNTING SYSTEM IN A REPRODUCTION MACHINE Filed Sept.30, 1965 Sheet FIG. 3

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March 4, 1969 J. R. CASSANO 3, 3

' G SY EPRODU MACHINE Filed Sept. 30. 1965 Sheet 4 0113 INVENI'OR.

I JAMES RCASSANO March 4, 1969 J. R. CASSANO 3,430,558

v SHEET COUNTING SYSTEM IN A REPRODUCTION MACHINE Filed Sept. 50. 1965Sheet 5 o! 13 Q m E ar a I N I llli' J Q i g i W///////// 8V Av 1 v h\Xs 0 an f I 6 i 'l 1 I t I: a l i I s i 4 \J L k. a a [11 I \E *1 7 m A4 a w/ /I/ V "3 fl I I .v A i 3 3; INVENTOR.

% a g JAMES RCASSANO March 4, 1969 J. R. CASSANO SHEET COUNTING SYSTEMIN A REPRODUCTION MACHINE Filed Sept. 50, 1965 Sheet 6 of 13 .0 Wm mm Hm% R W mm C 2 1 ,,A R S E M g Y B March 4, 1969 J. R..CASSANO SHEETQOUNTING SYSTEM IN A REPRODUCTION MACHINE Filed Sept. 30, 1965 SheetJAMES- R. cAssANb BY F/G. l5,

March 4, 1969 SHEET COUNTING SYSTEM IN A REPRODUCTION MACHINE FiledSept. 30, 1965 FIG. /4

J. R CASSANO Sheet 8 of 1s INVENTOR. JAMES R. CASSANO March 4, 1969March 4, 1969 3,430,558

SHEET COUNTING SYSTEM IN A REPRODUCTION MACHINE J. R. CASSANO SheetFiled Sept. 30, 1965 &

INVENTOR. JAMES RCASSANO BY y Q 04 r141 Arronwm J. R. CASSANO March 4,1969 SHEET COUNTING SYSTEM IN A REPRODUCTION MACHINE Filed Sept. 50,1965 /Z of 13 Sheet INVENTOR.

CASSANO BY JAMES R March 4, 1969 J. R. cAssANo 3,43

SHEET COUNTING SYSTEM IN A REPRODUCTION MACHINE Filed Sept. 50, 1965Sheet A? Of 13 FIG. 25

INVENTOR. JAMES RCASSANO United States Patent York Filed Sept. 30, 1965,Ser. No. 491,558 U.S. Cl. 101-132 Int. Cl. B411 9/10, 11/08 1 ClaimABSTRACT OF THE DISCLOSURE A reproduction apparatus of thepressure-transfer type incorporating a three-way roller bearing supportfor the rotatable copy drum and driving pressure roll, toggle type forcegenerating means for holding the pressure roll in pressure contact withthe copy drum, a foldable paper tray, automatic gripping means forattaching the trans-fer sheet to the copy drum, means for separatingcopies from the transfer sheet counting means to record the number ofmaster and copy sheets used, and programming control means adapted atthe last copy programmed to release the gripping means whereby thetransfer sheet is expelled with the last copy.

The present invention relates to reproduction machines and moreparticularly to an arrangement for cumulative sheet and master sheetcounting in a reproduction machine such as the pressure-transfer type.

Generally reproduction machines of the pressuretransfer configurationare two broad types. One type, known as a spirit duplicator, requires acopying fluid or spirit which moistens each copy sheet as it passesbetween a rotatable platen which supports a master or transfer sheet anda pressure roller. The spirit dissolves some of the dye on the mastersheet, and the resultant dissolved dyestuff is transferred to the copysheet as it is transported between the rollers.

Another type of pressure-transfer duplicating equipment combines theeffect of heat and pressure to effect transfer from a transfer sheet toa copy sheet. This type of equipment may take various forms and materialsuch as the use of fixing compositions for the dyes imprinted upon amaster sheet wherein heat is utilized to cause or enhance reactionbetween the dye and the fixing composition. Special circuits andtemperature control devices are provided in these duplicating machinesfor insuring optimum transfer conditions.

Significantly, the present invention takes on added importance in thatit may be devised in a reproduction machine having compact size,requiring a minimum of operative steps, involving a completely dryprocess and which may be quickly brought into operation by the mere pushof a button. With these advantages, the machine incorporating theinvention is particularly useful as a companion machine to theconventional typewriter, to be made a part of or an adjacent neighborthereto and serve to eliminate the need to make carbon copies by use ofthe typewriter. In fact, the machine, incorporating the presentinvention, derives its most useful benefit in that duplication of atyped original document may be accomplished solely by the machine, thuseliminating the cumbersome application of carbon paper to the typewriterand the burdensome manipulation of the carbon sheets in order to effecterasures of the carbon sheets and corrections to the original.

It is a principal object of the present invention to improve ofiiceduplicating machines for general copying use by utilizing a countingarrangement for cumulative counting of various types of sheet papertransported through the machine.

Patented Mar. 4, 1969 "ice Another object of the invention is to controlsheet counting by utilizing devices on a machine which are used solelyfor the type of sheet paper being counted.

Still another object of the invention is to arrange a counting system ina reproduction machine so that master sheets used in the machine arecounted cumulatively and the copy sheets produced by a master sheet orsheets is counted cumulatively but separately for the master sheetcount.

In order to accomplish these and other objects of the invention, thereis provided a dual counter arrangement in a duplicating machine of thetype which operates under a dry process requiring merely the applicationof pressure in order to effect transfer of information on an originaldocument to ordinary copy paper. The duplicating machine that will bedescribed in association with the present invention comprises arotatable drum for supporting therearound a transfer sheet and formoving first an original document therewith and then a sheet of copypaper. A roller is also provided and is arranged to be in pressurecontact with the drum by means of a toggle-joint force producingmechanism for effecting ink transfer. Each revolution of the drum isadapted to complete one reproduction of the original document, and aprogrammer device controls the operation of the drum and pressure rollerin cooperation with the other devices in the machine. There are includedin the machine means for driving the drum, guide means and registeringmeans for insuring accurate feeding and movement of the various sheetsinto and through the machine, and paper clamping devices, under controlof the programmer device, for controlling the movement or release of thesheets.

Further objects and advantages will become apparent after reading thefollowing description when taken in conjunction with the accompanyingdrawings, wherein:

FIG. 1 is an isometric view of the reproduction machine which embodiesthe present invention;

FIG. 2 is a front elevational View of the machine partly in section withother parts broken away;

FIG. 3 is a sectional view of the machine taken along the line 33 inFIG. 2 and showing a force generating mechanism utilized for exertingpressure between the copy drum and the pressure roller;

FIG. 4 is a schematic view of the drum and pressure roller in peripheralcontact to emphasize the crowned configuration of the roller;

FIG. 5 is a left-hand end view of the machine in FIG. 1 showing thedrive mechanism utilized therein;

FIG. 6 is a cross-sectional view of the copy drum taken along a verticalplane parallel with the axis of the drum and showing the drive mechanismfor the roller and the drum and the sheet material grippers; I

FIG. 7 is a schematic illustration combined with a force diagram of theforce generating mechanism;

FIG. 8 is a cross-sectional view taken along the line 88 in FIG. 2;

FIG. 9 is an enlarged sectional view of a detail taken along the line 99in FIG. 8;

FIG. 10 is an enlarged sectional view of another detail;

FIG. 11 is an enlarged view of one of the registration devices utilizedin the present invention;

FIG. 12 is a sectional view taken along the line 1212 in FIG. 11;

FIG. 13 is an enlarged view of one of the clamping mechanisms utilizedin the present invention;

FIG. 14 is a sectional view taken along the line 14-14 in FIG. 13;

FIG. 15 is a schematic illustration of the relationship of transfermaterial and structure used in cooperation therewith;

FIG. 16 is an enlarged fragmentary view of a detail of the invention inone position of operation;

FIG. 17 is an enlarged fragmentary view of the detail in FIG. 14 in aposition of operation;

FIG. l8 is an enlarged fragmentary View of the detail in FIG. 16 inanother position of operation;

FIG. 19 is a plan view of the programmer mechanism utilized in thereproduction machine;

FIG. is a side elevational view of the programmer mechanism;

FIGS. 21, 22, 23 and 24 are schematic views of portions of theprogrammer mechanism shown in other positions of operation; and,

FIG. is an electrical diagram utilized in the disclosed reproductionmachine.

The duplicating machine to be described herein is particularly adaptedfor printing out copies on ordinary copy paper by means of a pressuretransfer process involving a master or transfer sheet material producedas the first operative step in the use of the duplicating machine or ofany particular run of the machne. The master or transfer sheet, in turn,derives or acquires the information to be reproduced from an originalproduced independently of the duplicating machine, such for example, bytyping with a conventional typewriter.

In order to devise a transfer sheet that is usable with the presentmachine, the ink or pigment presented upon the transfer sheet must betransferable by the application of relatively high pressure. Productionof the transfer sheet may be accomplished by two methods:

(a) The direct method wherein the transfer sheet is typed along with theoriginal and a sheet of special carbon paper is positioned behind thetransfer sheet with the carbon ink facing the master, and

(b) The indirect method wherein the informational image is formed bytyping with a special typing ribbon onto the original from which theimage is transferred to a transfer sheet under pressure. The presentduplication machine is adapted to accommodate a transfer sheet producedby either method; however, it is preferred that the indirect method beemployed since this method would not involve the added manipulativesteps with a typewriter, that is, arranging an original, a carbon sheetand transfer sheet material in a typewriter and insuring adequatealignment of these sheets relative to one another. Essentially, theindirect method involves single-sheet typing.

In the direct method, the master sheet is generally made of wax paperwhich may be wax coated base stock paper, whereas in the direct method,the transfer sheet need not be wax coated. The ink formulation foreither the ribbon in the indirect method or the carbon paper in thedirect may include a small percentage of wax; a large percentage ofpigment, usually iron oxide or carbon pigment; and a modifier, such aspetroleum and chlorinated rubber, which serves as a binder.

In producing a transfer sheet by the indirect method, the ink from thetypewriter ribbon is transferred to the original sheet by the strikingof each typewriter key, as is the case with single copy typing. Thetyped original is usable as such and may be mailed or routinely handledas an ordinary typed ribbon copy. Reproductions of the original can bemade by means of the present machine in view of the fact that a portionof the ink on the original will be transferred to the transfer sheetmaterials by the application of pressure. To reproduce copies, theoriginal sheet and atransfer sheet are aligned in the feed tray with thetyped copy in contact with the coated surface of the transfer sheet andfed into the machine incorporating the present invention wherein highpressure is applied as the sheets are rolled through the pressure areain the machine. This action transfers the ink from the original to thetransfer sheet. The transfer sheet is retained in the machine while theoriginal is fed out. To make copies, a sheet of ordinary copy paper isplaced in the feed tray where it is automatically registered with thecopy on the transfer sheet and then rolled through the pressure area ofthe machine. With the application of pressure, some of the ink istransferred from the transfer sheet to the copy sheet. This step may berepeated in order to produce any number of copy sheets, for example, tencopies or more, depending upon the ink depth and the porosity of thepapers utilized.

Referring to FIGS. 1 and 2, the duplicating machine embodying thepresent invention includes a drum 10 mounted for rotation on a basecasting 11 having vertically extending left-hand and right-hand sideplates 12 and 13 spaced inwardly a slight distance from the respectiveends of the base. Also mounted for rotation on the base 11 is a pressureroller 14 having its internal diameter in the center area thereofslightly larger than at the ends and tapering between the center areaand the ends thus providing a crown roller configuration.

As shown in FIG. 3, which illustrates the one end of the drum 10 and theroller 14 and their supporting structure and which is similar to theother end, the drum and the pressure roller are confined and supportedfor rotation on three bearing rollers 15, 16 and 17 arranged at theapexes of an isoceles triangle, and a fourth roller bearing 18 rotatablysupported on a pivot pin 19 and arranged for limited movement. Thebearing rollers 15, 16 and 17 are arranged in similar fashion at bothends of the base 11 and are each rotatably mounted by fixed pins 20secured to and between the side plate 12 and an end plate 21 at the leftend of the machine, as viewed in FIG. 2, and between the side plate 13and an end plate 22 at the right-hand end. The fourth bearing roller 18is mounted on a lever system and biased into engagement with thepressure roller 14. Further details of the roller and drum supportingarrangement will be described hereinafter in the description of theforce generating mechanism for the roller 14.

In FIG. 4, the crown configuration of the pressure roller 14 is shownschematically in relation to the drum. The tapered diameter from thecenter area, which is relatively fiat toward the ends of the roller, asshown, are exaggerated in order to facilitate description. Good resultshave been attained from a configuration wherein each tapered end of theroller is approximately onethird of the length of the roller as is thecenter area, and the difference in diameter between the ends and thecenter area is one or two thousandths of an inch for a two-inch diameterroller.

In operation of the machine, during transfer there is a sheet of paperand a transfer sheet between the roller and the drum. Extremely highlinear pressure or force will exist along the linear contact of theroller and the drum with the paper and the transfer sheet therebetweenas transmitted by the supporting rollers 15, 16, 17 and 18. Because thepaper and transfer sheet are compressible and also because thesupporting rollers 15, 16, 17 and 18 are beyond the edges of the paperand the transfer sheet, the roller will be deflected; and if thepressure roller were of straight configuration instead of crown, thepressure at the ends of the linear contact would be greater than at thecenter. The effect of this condition would be the production of copiesthat were darker at the edge portion of the sheet and lighter in themiddle area. In addition, this uneven pressure axially along the drumproduces a component of force which runs axially inwardly along thelinear contact, and this component of force will result in the sheetbeing processed becoming wrinkled and creased out of shape.

With the provision of a crowned configuration to the pressure roller,the deflection of the roller caused by the extremely high pressure isbalanced by the beam strength of the roller thereby resulting inparallel linear surfaces for the linear contact and even pressuresthroughout the contact. With the presence of an even pressure, thetransferred image will be even in contrast or density. In addition, thebalanced or even pressure will eliminate the axially directed componentof force which wou d have produced wrinkling of the sheet.

Within the drum there is mounted a drive motor 24 which is held in afixed position externally by a plurality of screws 25 extending throughthe end plate 21. The diameter of the motor casing is slightly smallerthan the internal diameter of the drum in order to provide sufficientclearance therebetween for the rotational movement of the drum. Thedrive shaft 26 for the motor extends through a suitable opening in theplate 21 and terminates in a pinion gear 27 secured thereto. (See FIG.5.) This gear meshes with an enlarged gear 28 rotatably mounted with abearing 30 upon a screw 31 threaded into a flanged bushing 32 secured tothe end plate 21. (See FIG. 6.) A smaller gear 33 secured to the gear 28and rotatably mounted on the bearing 30 meshes with a drive gear 34 forrotating the pressure roller 14.

As shown in FIG. 6, the drive gear 34 is secured by a screw 35 to acylindrical thrust member 36 through which the screw slidably extendsand which is slidably received into the left end of the roller 14. Themember 36 is formed with an enlarged cylindrical portion 37 whichengages the internal surface of the roller 14 and a reduced section 38which extends out of the roller and through a suitable opening formed inthe end plate 21. The gear 34 i held against one end of the section 38by the screw 35 which is threadedly received into a cylindrical hubclamp 39 also positioned within the roller 14 and engag able with theinternal surface thereof. A sleeve 40 encircles a reduced section 41formed inwardly of the thrust member 36 and also a reduced section ofthe clamp 39 which is spaced a slight distance from the extreme inwardend of the member 36. The sleeve 40 engages the internal surface of theroller 14 and is positioned to engage at both ends O-rings 42 placedupon the respective reduced portions of the member 36 and the clamp 39.The screw 35, member 36, clamp 39 and the sleeve 40 are all in axialalignment with the roller 14.

As the screw 35 is tightened, the clamp 39 is drawn toward the member 36on a pin 43 which prevents rotation thereby compressing the O-rings 42against the internal surface of the roller 14 and also to secure thedrive gear 34 against the outer end of the section 38. With thisarrangement, as the gear train comprising the gears 27, 28, 33 and 34 isdriven by the motor 24, the gear 34 will impart rotation to the roller14 through the thrust member 36 and the O-rings 42. During rotation ofthe roller 14, the same is held against axial movement by the end plates21 and 22 which are normally spaced a slight distance from thrustbearings 44 secured at each end of the roller.

As will be presently described, the drum 10 is driven for rotation byits frictional engagement with the pressure roller 14 which itself isdriven by the motor 24. Neither the drum nor the pressure roller utilizea conventional shaft either for producing rotation or supporting thesame. As previously stated, the drum and the pressure roller aresupported for rotation by a set of bearing rollers located at each endof the machine, one set being located between the side plate 12 and theleft end plate 21 and the other set being located between the .sideplate 13 and the right end plate 22. In order to accomplish theselocations, each of the side plates 12 and 13 is formed with centralenlarged cutouts 45, see FIG. 3, for the plate 12, in order to permitthe extension of the drum 10 and roller 14 beyond these side plates.

One set of bearing rollers includes the three fixed rollers 15, 16 and17 which are located at the apexes of an isoceles triangle having theaxis of the rollers 15 and 16 located on the base of the triangulararrangement and one of the sides S extending between the axis of theroller 15 to the axis of the roller 17 while the other side S extendsfrom the axis of the roller 16 to the axis of the roller 17. As shown inthe schematic force diagram of FIG. 7, the

axis A of the drum is located on the bisecting line B for the anglebetween the sides S and S The pressure roller 14, positioned between thedrum 10' and the bearing roller 17, is held in this position by theroller 18 and has its axis A slightly offset with respect to thebisecting line B. The axis A is also slightly offset from a planedefined by the axis A and a line of peripheral contact between theroller 17 and the pressure roller 14. With this arrangement, relativelygreat pressures on the order of to 300 lbs. per linear inch may beachieved at the line of contact between the drum surface and the surfaceof the pressure roller by the application of a relatively smallgenerating force.

In order to accomplish this high linear force, each of the rollers 18 ismounted on a force producing lever 46 (see FIG. 3), which comprises twoidentical lever plates 47, 48 connected together and in spaced parallelrelationship by suitable pins 50. Each lever 46 is pivotally mounted atone end by a pivot pin 51 between the plates 12 and 21 on the left sideof the machine and the plates 13 and 22 on the right side. The roller 18is supported for rotation between the lever plates 47, 48 on the pivotpin 19, which is located inwardly of the lever 46 from the pivot pin 51therefor. At the other end of the lever 46 there is provided a springbiasing means comprising a coil spring 52 held in compression between aretaining cap 53 secured on the lever and a seat 54 secured to andbetween the plate-pairs 12, 21 and 13, 22.

As shown in FIG. 3, the spring 52 is adapted to rotate the lever 46clockwise about the pin 51. This force is represented by the arrow F inthe force diagram of FIG. 7. In this action, the roller 18 iscontinuously pressed against the pressure roller 14 which, as a resultof this force, will react to wedge itself between the fixed roller 17and the drum 10. The installation of these structural parts is such thatthe axis A for the pressure roller 14 is slightly displaced from thebisecting line B or, in elTect, is offset relative to the plane definedby the axis A and the line of contact between the bearing roller 17 andthe pressure roller 14 and thereby functions under the principles oftoggle-joint mechanics wherein the resistance force opposing themovement of a toggle-joint connection by a given applied force isinversely proportional to the distance between the connection and a linethrough the two points of resistance. The applied force illustrated bythe arrow F in the arrangement diagrarnmed in FIG. 7 is the result ofthe force F produced by the compression of the spring 52 working acrossthe movement arm measured from this spring force to the pivot pin 51.The effect of the force F is transmitted to the roller 18 as the force Fand since the moment arm between the axis of this roller and the pivotpin 51 is relatively short, the transmitted or applied force F on theroller 18 is relatively great or many times greater than the force F Infact, the dilference in the forces F and F is determined by the ratio oftheir effective moment arms, which, for the illustrated arrangement, isapproximately 6 to 1.

The applied force F continuously produces a wedging action in the formof a component of the force applied radially of the pressure roller 14thereby resulting in a force F between the contacting peripheries of theroller 14 and the drum 10. This force F is applied linearly along thedrum and roller and parallel to their axes and is the result of thetoggle-joint structural arrangement which produces a still greater forceF than the applied force which in the illustrated case is the force F Aspreviously stated, the resistance force in a toggle-joint arrangement,which in the present arrangement is represented by the force F isinversely proportional to the distance between the point at which theapplied force or a component of the applied force is applied and theover-center point in the toggle-joint. In the present arrangement, theformer point is the axis A and the latter point is on the line B or onthe plane defined by the axis A and the line of contact between therollers 17 and 14. Since the distance between the axis A and the line Bor the above-defined plane is very short, a relatively large resistanceforce F may be produced by a relatively small force F being appliedradially of the pressure roller tending to bring the axis A intoalignment with the plane. In effect, the wedging or toggle-joint actionis produced by the arrangement wherein the distance between the roller17 and the rollers 15, 16, which limit the radial outward movement ofthe drum and the pressure roller, is somewhat less than the sum of thediameters of the drum and pressure roller; and this component of forceapplied radially to the pressure roller attempts to toggle thedrum-pressure roller combination through this slightly shorter distance.

For purposes of good pressure transfer, as will be presently described,the force F which is used for effecting transfer should be between 175and 300 lbs. per linear inch. This relatively high force can begenerated by a relatively lesser force F which, in turn, is produced bya still lesser force F Conversely, a relatively light force F is adaptedto generate a relative high force F by means of the lever arrangementcompressing the elements 18, 46, 51 and 52 and the toggle-jointmechanism comprising the elements 15, 16, 17 and 18 and 46.

From the foregoing it will be apparent that the linear force or pressurebetween the drum and the pressure roller 14 is accomplished withrelatively little initiating force. It will also be appreciated that thecopy drum 10 and the pressure producing roller 14 therefor are notmounted for rotation on shafts which would flex somewhat if subjected tothe high pressures needed to effect pressure transfer. Instead, the drumand the pressure roller are mounted for rotation by the rollers -18 aswell as each other in order to provide better and wider distribution ofthe great pressures which are necessary to effect good copy transfer.

Means are provided for guiding sheets of material such as transfersheets, copy sheets and originals into, through and out of the machine.Other means are also provided to establish a relationship between thesheets for effecting programmed handling as the various sheets areconveyed through the machine and includes sheet registering devices andsheet clamping mechanisms.

In guiding sheets of material into the machine, a paper tray, generallyindicated by the reference numeral 55, is provided and is arranged abovethe machine to direct a single sheet or double sheets to the vicinity ofthe nip of the drum-pressure roller arrangement. The tray is shown fullyextended and in position to guide sheets into the machine; however, itmay be retracted and pivoted from the position indicated by solid linesin FIG. 8 to the dotted position in order to eliminate the chance ofdamage when not in use and to blend into the contour of the machine.

The tray 55 includes a guide plate 56 upon which sheets of material areadapted to rest when the leading edges thereof are in the nip of thedrum-pressure roller arrangement. The guide plate has fixed theretoalong both longitudinal edges a frame member 57 formed with longitudinalslots 58 into which the edges of the plate are fixed. The plate 56 maybe extended outwardly by an extension plate 59 slidably received inslots 60 formed parallel to and above the slots 58. Magnet strips 61secured to the top surface at the outer edge of the guide plate 56 andto the bottom surface, inner edge of the extension plate 59 serve tohold the plate 59 in its extended position when moved thereto. Themagnet strips are arranged to intercept each other as the extensionplate 59 is pulled out in order to limit the travel of this plate andare of sufficient magnetic strength as to maintain the plates in anextended position until manually retracted wherein the strips 61 areforceably detached for permitting movement or telescoping of theextension plate into the tray.

As shown in FIGS. 2 and 10, the forward edge of the guide plate 56 issecured as by welding to a support plate 62 which extends along thelength of the machine and has at each end thereof a turned down ear 63having slots 64 through which a rod 65 is adapted to project. The rod 65extends longitudinally of the machine and its ends may terminate insuitable clearances recesses formed in the side plates 12, 13. The rod65 is supported in a fixed position relative to the machine by a paperguide plate 66 having turned tabs 67 which encircle the rod near bothends thereof. The plate 66, in turn, is spot welded to a bracket plate68 formed with bent extensions 69 at the ends thereof and which may bedetachably secured to the machine casing, illustrated generally by thenumber 70, by suitable screws.

Between the rod holding tabs 67, the plate 66 is formed with an edge 71which is utilized to hold the tray 55 in the angled elevational positionshown in FIG. '8. This edge is adapted to be grasped by the forward edgeof the guide plate 56 and the adjacent forward edge of the support plate62, the latter edge being formed into a turned portion 72 spaced fromthe plate 62 a distance equal to the thickness of the edge 71.

In arranging the tray for paper supporting use, the same is pivotedabout the rod 65 and pulled upward and to the rear of the machine at thesame time in order to move the ears 63 until the rod 65 is at the lowerends of the slots 64. This will permit the bent portion 72 to clear theedge 71 of the plate 66. When shown in the position illustrated in FIG.8, the tray 55 is gently pushed downwardly and forwardly of the machinein order to bring the edge 71 between the adjacent lower edge of theplate 56 and the turned portion 72 and firmly locked therebetween. Theextension plate 59 may then be extended upwardly in order to provide afully extended tray 55 for sheets of paper.

The bent extension 69 also supports an upper paper guide device 73 whichcooperates with the lower paper guide plate 66 for guiding thetransporting of various sheets of material into the machine. A normallyopen switch S2 (see FIG. 10) connected to the motor 24 is mounted in themachine with its actuator in the input paper path so that the machinecannot be capable of operation without paper in the chute therebypreventing damage to the original sheet or master.

In emerging from the machine, the sheets of material are guided by anupper stripper element 74 and a lower chute 75 (see FIGS. 8, 16 and 17).The stripper 74 is pivotally retained by outwardly projecting pins 76 tothe machine casing and is formed along one longitudinal edge with atleast two tongue portions 77 (see FIG. 2) which are preferablyknife-edged in their outer extremities. A torsion spring 78 secured atone end to the machine casing 70 and at its outer end to the stripperserves to continuously force the knife-edged tongues 77 against thelower section of the pressure roller 14 on the output side of the nipfor the drum-pressure roller combination. As a sheet or sheets ofmaterial are forced out by the rotation of the drum and the pressureroller, the sheet or sheets are prevented from adhering to the roller 14and are stripped off this roller by the stripper 74.

The chute is spaced slightly lower than the stripper 74, as shown inFIG. 8, and includes an upper plow section 79 having a plurality ofteeth 80 (see FIGS. 15 and 16) arranged along the outer edge thereof andspaced a slight predetermined distance from the periphery of the drum.This spacing is provided by end plates 79a (see FIG. 2) made integralwith the chute 75 at the ends thereof beyond the edges of a sheet movingbetween the drum and the pressure roller. The plates 79a have short andnarrow bearing surfaces which conform to and contact the drum when thechute is in paper stripping position, as shown in FIG. 8. With thebearing plate against the drum, the teeth 80 will be spaced apredetermined distance from the drum surface.

The purpose for the spacing relative to the drum periphery is to providesufiicient clearance between the plow teeth 80 and the drum surface sothat a master sheet can be supported on the drum without danger ofinterference or damage to the master caused by the plow teeth.

The chute 75, the end plates 79a and the teeth 80 are movably mountedrelative to the periphery of the drum by being secured to the frontcover 70 which itself is pivotally mounted on the machine base bysuitable pivot pins 80a secured to the casing and rotatably supported inthe end plates 12, 13. As shown in FIG. 5, the casing 70 may be swungoutwardly about the axis line defined by the pins 80a at each end of themachine.

The chute 75 is adapted to be held at this predetermined distance fromthe drum periphery and is made movable relative thereto by the use oftwo sliding wedge blocks 81, each of which is adapted to be drivenmanually by a thumb tab 81a through a suitable opening 81b formed in thechute 75 and through an aligned square opening having a straight bearingedge 810 formed in the machine casing, such as the plates 12, 13. Thewedging taper of the blocks 81 will, when driven, slide along each ofthe straight edges 810 for pressing the end plates 79a against the drumand drawing the chute 75 snugly into a secure position upon the machinebase wherein the edges of the teeth 80 are spaced the predetermineddistance from the periphery of the drum. This pressure against the drumand the drawing of the chute will cooperate with the pivot pins 80a forproviding a rigid support for the front casing 70 and the chute 75. Whenit is desired to replace the chute or to move it away from the drum forclearing the drum of paper jams or permit cleaning of the drum, theblocks 81 may be pulled toward each other for permitting detachment fromthe openings and the machine. The casing 70 may then be swung outwardlyand upwardly to expose the drum and pressure roller. Repositioning ofthe casing 70 and the blocks 81, as previously described, will againreturn the teeth 80 precisely to their previously occupied positionsrelative to the drum.

Because of the critical predetermined spacing between the drum peripheryand the adjacent portions of the teeth 80, it is important that theteeth be returned to a precise positioning each time the casing 70 ismoved. This is accomplished by the pins 80a which insure that theforward edges of the teeth will be positioned parallel to the axis ofthe drum, and by the bearing surface on the plates 79a and the wedgingof the blocks 81 which insure that the spacing between the teeth and thedrum periphery will be uniform throughout the length of the drum andwill be the same as the previous positioning of the chute 75. In effect,then, the blocks and the cooperating structure insure that the chute 75will automatically become aligned for each use of the blocks andcooperating structure.

As previously indicated, the machine is provided with means forestablishing positionable and operative relationships between the sheetswhich are introduced into the machine in order to effect programmedhandling of the machine operation. These means include sheetregistration devices and clamping devices as well as various operativemechanisms associated therewith.

Before commencing the description and operation of these devices, abrief outline of the sheet manipulation that occurs during a completemachine cycle of operation will now be made. During the first stage ofoperation of the machine, both a blank transfer sheet and an originalwhich has been typed or otherwise impirnted with an appropriate inkformulation, which will readily transfer from one sheet to another bythe application of extreme pressures, are inserted preferablysimultaneously into the nip of the drum-pressure roller combination. Itis imperative in this step that the transfer sheet be applied so that itwill be in contact with the drum 10 during rotation thereof and that thetype script to be copied be in contact with the transfer sheet. Both thetransfer sheet and the original are driven through the nip of thedrum-pressure roller and during the drive, which in this stage will be asingle revolution of the drum, the transfer sheet will become clamped tothe drum and remain 10 so while the original is immediately stripped anddirected out of the machine by means of the guide 74 and the chute 75.

The next step in the cycle of operation requires the insertion ofindividual sheets of copy paper into the machine. During this step, theimage on the transfer sheet is transferred to each copy sheet as theyare inserted indi vidually in the machine. During each transfer, thetransfer sheet remains on the drum, and the copy sheet is stripped outof the machine until the last programmed copy sheet has been made. Asthe last copy sheet is being stripped out, the transfer sheet is alsobeing removed from the machine so that both sheets more or less areremoved simultaneousiy.

For automatically controlling positioning of the original sheet ofmaterial from which a transfer sheet will derive its inked image and forthe automatic positioning of subsequent applied sheets of copy paper,the drum is provided with a plurality of registration devices 82 eachhaving a pin 83 against which the leading edges of copy sheets or theoriginal sheet abuts and which are arranged in a line parallel to theaxis of the drum but coincident with the periphery thereof. As shown inFIGS. 11 and 12, the pin 83 extends radially of the drum beyond theperiphery thereof and is formed with an enlarged diameter section 84having an annular shoulder 85. The registration device 82 is adapted toslide within an inverted cylindrical element 86 tightly fitted into anopening 87 formed in alignment in the wall of the drum 10. A spring 88normally held in compression within the element 86 between the bottomclosed wall thereof and an inner wall of the shoulder thereby normallybiases the registration pin 83 outwardly and the shoulder 85 slightlybeyond the periphery of the drum surface. In order to maintain the pin83 and the section 84 within the cylindrical element 88, the pin 83extends within the element 86, through the opening in the bottom wallthereof and terminates in a split and flared end 89 which preventsextraction of the pin 83 from the device 82.

As shown in FIGS. 15, 16 and 17, the registration pins 83 are adapted toengage a sheet of material, such as copy paper or an original, indicatedby the reference letter P. As shown, the sheet P, when laid upon thepaper tray 55 or when shoved toward the nip of the drum-pressure rollercombination, is prevented from assuming any other position except thatshown in FIGS. 15 and 16. The illustrated positions are those assumed bythe original P and the transfer sheet just prior to initial operation ofa production cycle. The forward edge of the sheet P is shown inengagement with the pins 83 which are held slightly downwardly by thetrailing edge of the paper guide 73. This engagement of the pins 83 withthe lower surfaces of the upper guide 73 insures that the leading edgeof a paper sheet will not go above or beyond the registration deviceswhen the paper is inserted into the machine. Lowering of the pins 83also maintains the shoulders 85 below the periphery surface of the drumand out of the way when sheets of paper are introduced into the machinethus insuring that an original document or copy sheet is always againstthe registration pins 83 just prior to start of machine operation. Inaddition, by maintaining the pin 83 and shoulder 85 in a loweredposition prior to start of operation also minimizes the chances that theedge of a sheet of material will be turned toward the drum periphery bythe friction produced by the pins 83 as they are completely lowered bythe roller 14 during machine operation. Normally, the leading edge of asheet of paper is held above the periphery of the drum by the shoulder85, as shown in FIG. 1'7, and which will be discussed hereinafter. Agroove 6 is formed in the lower surface of the guide 73 for each of theregistration pins and prevents the leading edge of the sheet P frombeing placed above the pin 83 or to come between the top of the pin andthe lower edge of the guide 73. As previously stated, the sheets P andT, when introduced into the machine, assume the initial position shownin FIG. 16 where the edge of the sheet P is against the pins 83.

The drum is also provided with a plurality of clamping devices whichserve to selectively clamp a transfer sheet, designated by the letter T,to the drum periphery. These clamping devices, designated generally bythe reference numeral 90, are spaced alternately with the registrationdevices 82 and are arranged along a line parallel to these devices butspaced slightly forward therefrom. As shown in FIG. 15, the transfersheet T is formed with a scalloped forward edge having extension tabs 91which are each applied to one of the clamping devices. Since there arefour extension tabs 91, then only four clamping devices will benecessary. It will also be seen in FIG. 15, that the clamping devices 90and the registration devices are arranged such that the tabs of thescalloped edge of the transfer sheet T leads, or is forward of theleading edge of the copy sheet P.

The details of one of the clamping devices are shown in FIGS. 13 and 14.Each device includes a moulded plastic block 92 adapted to extendthrough a suitable circular opening 93 formed in the wall of the drum10. A pair of parallel arranged mounting rods 94 extending through eachof the blocks and along the entire length of the drum (see FIG. 6) serveto hold each of the blocks in proper position within their respectiveopenings 93. These rods are mounted in and between bearing brushings 95which are held into the ends of the drum by these rods and a third tierod 96 located diametrically of the rods 94. Suitable screws 97 may beutilized to fasten the ends of the rods to their respective bushings 95.

Each block 92 is formed with a lower enlarged section 98 which iscontained within the interior of the drum 10 and through which themounting rods 94 project. Formed integrally with the lower section 98 isan upper reduced section 100 which fits within the opening 93 andterminates in an upper surface 101 slightly below the plane of the upperend of the opening 93. From FIG. 13, it will be seen that the section100 is curved at its forward and rearward ends to fit snuggly into theoppositely curved sides of the opening 93 thereby precisely locatingeach of the clamping blocks and maintaining these in a fixed positionagainst forces which will act along circumferentially of the drum.

Both the sections 98 and 100 of each block are formed with a continuouscentral recess 102 which, when traced radially of the drum, is opened atthe bottom of the section 98 and closed at a point within the uppersection 100 slightly below the top surface 101. When traced axially ofthe drum, the recess 102 extends completely through or, in other words,is open at both sides of the block 92. However, the recess, when tracedaxially, is partially closed by the metallic side plates 103, 104, onelocated on each side of the upper section 100 of a clamping element thatis movably mounted upon the block 92. This clamping element, generallyindicated by the reference numeral 105, includes the parallel arrangedside plates 103, 104 which are formed with upper edges 106, 107,respectively, that are inclined upwardly toward the rear of the block92, a rear plate 108 integral therewith and with an extension tab 110 ofthe rear plate. The tab extends above the side plates 103, 104 and therear plate 108 and is bent toward the forward end of the block 92 at apoint slightly above the highest inclined point relative to the upperedges 106, 107. In order to accommodate the rear plate 108, the uppersection 100 for the block 92 is formed with a slot 111 into which theplate 108 may slide radially relative to the drum 10. Preferably, theclamping element 105 is formed from a single piece of stamped springmetal, thereby permitting limited flexing of the tab 110 duringoperation of the clamping device.

The clamping element 105 is adapted for vertical movement, as seen inFIG. 14, or radially relative to the drum axis in order to accomplishclamping and unclamping of the scalloped leading edge of the transfersheet T. In the position shown in solid lines in FIG. 14, the tab 110engages the top surface 101 of the block 92 and is normally held in thisposition by a spring 112 held in compression within the recess 102. Thisspring at one end engages the upper wall of the section and at its otherend is forced against a pin 113 which extends through the side plates103, 104 and the recess. When in clamping position, one of the tongues91 of a transfer sheet is adapted to be held between the tab 110 and thetop surface 101. The purpose of the inclined upper edges 106, 107 is toguide the leading edges of the tabs 91 fully into the space be tweenthese edges and the clamping tab 110 in order to insure full alignedgripping of all of the tabs 91. In addition, the incline to the upperedges permits the raising of the leading edges of the tabs 91 above thesurface of the drum during stripping of the transfer sheet.

Means are provided to release each of the clamping devicessimultaneously, and to this end the drum has mounted internally thereinand parallel to its axis a release rod 114 which is adapted to beinserted in the recess 102 in each of the clamping block positions 98.As shown in FIGS. 6 and 14, the rod 114 is arranged between the tie rods94, is rotatably retained at one end of the drum and extends out theother end thereof terminating in a cam actuator element v115 secured tothe end of the rod. The rod is formed throughout its length or at leastin that portion immediately below each clamping device 90 with a flatcam surface 116 upon which the lower edges 117 of the side plates 103,104 for each clamping element are forced by their respective springs112. Normally, the rod 114 is held by its own mounting means in theposition shown in FIGS. 14 and 18 wherein all of the clamping tabs areheld down against the top surfaces 101 of the clamping blocks. In orderto effect this condition, the cam surface 116 must be parallel with thebottom edges 117 in order to present the latter with the longestpossible distance they can travel.

For release of the transfer paper or to maintain the clamping devices inunclamped positions prior to the insertion of a transfer sheet into themachine, as will be described below, the release rod 114 is rotated inorder to cam the edges 117 upwardly thereby forcing each of the clampingelements 105 upwardly against the bias of their respective springs 112.This rotation of the rod will simultaneously release all of the clampingdevices 90. Release of the rod to assume its normal position, that is,removal of any force which will cause rotation, will permit a spring 118(see FIG. 6) which encircles the release rod 114 to return the same toits original position against a stop (not shown). In order to eliminateany restrictive force upon the extension tabs v110 when the same arefully opened at the end of a production run, as shown in FIG. 16, thepaper guide 73 is formed with grooves similar to but deeper than thegrooves G for permitting total clearance for the tabs 110.

The reproduction machine is provided with a programming mechanism whichcontrols the operation of the machine once it is set in motion and incooperation with a copy counting mechanism and an electrical controlcircuit. The programming mechanism, illustrated in operative detail inFIGS. 19 through 24, is located in the machine between the end plate 22to which it is attached and the machine casing, see FIG. 2. Generallyindicated by the reference numeral 120, the programmer comprises anumber of control levers which assume various motions and positionsduring a single and complete reproduction cycle. Such a cycle requirestwo complete rotations of the drum 10, one to convert the master ortransfer sheet T into a master and one revolution to produce one copyfrom the transfer sheet. The structure of the programmer mechanism andthe counter mechanism is such that every reproduced copy desiredrequires one full rotation of the drum. For any series or multiple copyprogram, there will be as many durm rotations as there are programmedcopies to be made plus one additional rotation to produce the mastertransfer sheet.

The programmer mechanism 120 comprises a first lever 121 pivotallymounted on and arranged parallel to the plate 22 by a pin 122. It ispreferred that the lever 121 be spaced from this plate by an integralboss 123 in order to provide space between the lever and the plate 22for additional structure. A torsion spring 124 is anchored at one end onthe pin 122 and the lever 121 and normally biases the levercounterclockwise, as viewed in FIG. 19, toward a stop 125 secured to theplate 22. However, other structure normally limits this rotation of thelever, as will be presently described.

Counterclockwise rotation of the lever 121 is prevented by theintervention of two individually controlled actuating members which needrelease in order to allow further rotation of the lever. One of theactuating members is in the form of a cam lobe 127 positionable in thepath of a cam surface 128 of the lever and which is integral with andradially protrudes from a circular element 129 having a circular ratchet130 formed thereon together with a copy indicating and setting knob 132.The element 129, ratchet 130' and the knob 132 are rotatably fastened tothe plate 22 by a screw 131.

The other actuating member which releasably impedes rotation of thelever 121 is a latch element 133 normally within a recess 134 formed inthe free end of the lever. The latch 133 is integral with a boss 135secured to a shaft 136 to be rotatable therewith. The shaft 136 ismounted for limited rocking or rotation within suitable apertures formedin the machine side plates -12, 13 and has secured thereto a push bar137 accessible from the exterior of the machine to permit actuation by amachine operator. Manual depressing of the push bar 137 will producecounterclockwise rocking of the shaft 136, as viewed in FIG. 19, withconsequent movement of the latch element 133 out of the recess 134.

A torsion spring 138 having one end anchored in the plate 22 and itsother end fastened to the boss v135 serves to normally maintain the pushbar 137 in its uppermost position, the one illustrated in FIG. 19, onceit has been actuated. The latch 133 is formed with a thin narrowcross-section which offers some limited resiliency to the element. Whenthe bar 137 is rotated back to its initial position by the spring 138and after the operator has released the bar, the latch element willremain out of the recess 134 and against the upper end of the lever 121under its own resilient force. When the lever is rotated clockwise, theelement will snap back into the recess 134 when in alignment therewith.

The programmer mechanism 120 is provided with a second lever 140 madeintegral with the boss 135 and therefore pivotally mounted with theshaft 136. As shown in FIG. 20, the lever 140' is in a plane parallelwith the plane of the lever 121 and very close thereto and is providedwith a cam surface 141 cooperable with the cam lobe 127 in the samemanner as the surface 128. However, the lever 140' is also provided witha second cam surface 142 adjacent the surface 141 and angled therefromby approximately 90. This cam surface extends horizontally above thelobe 127 and is normally biased in this position in contact with theupper tip of the lobe by the torsion spring 138 which acts upon theshaft 136 and the boss 135. The lobe 127, in effect, prevents rotationof the lever 140' when the machine is in shutdown condition, as shown inFIG. 19.

A third lever 144 is also provided in the mechanism 120, and this leveris pivoted at its upper end by a pin 145 secured to the plate 22. Atorsion spring 146 having one end secured to the plate 22 and its otherend secured to the lever 144 normally biases the same in acounterclockwise direction. The lever 144 is in a plane parallel withthe planes of the levers 121 and 140 and is spaced inwardly therefromtoward the plate 22. Pivotally mounted by a pivot pin 147 on the lever144 in a plane parallel thereto and spaced therefrom toward the lever121 is a latching lever 148. A torsion spring 150 normally biases theprojecting end 152 of lever 148 in a clockwise direction and against alatch stop 151 formed on the lever 121.

The programmer mechanism 120 is also arranged to cooperate with threeswitches which may be suitably mounted on the end plate 22 at levelswhich will permit actuation by the levers previously described. Theconditions and function of these switches will be discussed hereinafterduring the description of the operation and the electrical system.However, their cooperation with the levers will be briefly stated atthis point in order to better illustrate the sequences of events thatthe programmer experiences.

One of the switches, S-1, the push bar or the start switch is providedwith a switch actuator 153 cooperable with a tab 154 formed on the lever140. The second of the switches, the hOme switch 5-3, is provided with aswitch actuator 155 cooperable with a boss 156 formed on the camactuator 115. The third of the switches, the master count switch S4, isprovided with a switch actuator 157 made cooperable with a cam edge 158formed on the middle section of the lever 121 to be actuated therebywhen this lever is pivoted from the position shown in FIG. 19 to the oneshown in FIG. 21.

To set the programmer 120 and, consequently, the machine in operation,the operator must perform two actions after sheets of material have beeninserted into the machine. When not in use and at the close of aprevious operation of the machine, the programmer and its controlstructure are in the positions shown in FIG. 19. The first step oraction to be performed is to dial the number of copies to be produced onthe machine, and to this end the operator rotates the knob 132 until aselected number from the numerals 160 is in registry with suitableindicia or reference point on the machine casing. For purposes of thepresent description, it will be assumed that the knob 132 has beenrotated to effect the production of three copies. In FIG. 21, theratchet 130 has been rotated counterclockwise in the direction of thearrow to effect this selection of copies to be made. A spring clip 161(see FIG. 19) engageable with the individual teeth of the ratchet willreleasably hold the ratchet into any position it is rotated.

In rotating to the position shown in FIG. 21, the cam lobe 127 was alsomoved to thereby release its engagement with the cam surfaces 128 and142. As previously stated, the clamping shaft 114 is normally biased toa predetermined position by the return spring 118, and this position isone wherein the program control actuator and a cam 163 formed thereonassume the position they take in FIG. 21. Such a biasing action by thespring 118 also results in the closing of the clamping devices 90.However, in order to condition the machine for ease of operation and torender it accessible for more immediate use, the shaft 114 is normallyheld in a second predetermined position to maintain the clamping devices90 open when the machine is in ready-to-use condition. In thiscondition, sheets of paper may be inserted into the machine which isdisposed to clamp the transfer sheets T along the scalloped edgethereof. The second predetermined position of the shaft 114 ismaintained by the engagement of the cam 163 against a cam surface 164formed on the lever 121, as shown in FIG. 19. This will maintain theclamping tabs 110 in their unclamped positions when the machine isstanding idle, as shown in FIG. 16.

The second operative step to be performed by the operator is to depressthe touch bar 137 momentarily. This action will cause the upwardmovement of the latch element 133 in order to free the lever 121 forcounterclockwise rotation. Since the cam lobe 127 was previously movedout of the path of movement of the cam edge 128, the lever 121 is nowtotally free to rotate until it abuts the stop 125. In so moving, thecam surface 164 also moves out of the path of rotation for the cam 163allow-

